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Space Telescope ProgramsHubble Observatory
HST-COS FUV PER 11/8/00
FUV Detector SystemEnvironmental Qualification Overview
Dr. Barry Welsh
FUV Project Manager
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FUV Detector System Test Flow
Vibration TestPost-Vibration
FunctionalEMI/EMC
MCP UV scrubFinal Pre-Ship
functionaltesting
Ship to UCoCleanliness Certification
• Verify w/ HV On, Stimsactive, Ion Pump On
• Conducted Emissions(HV on)
• Conducted Susceptibility(Stims on)
• Thermal Cycles Long-Form Detector
Functional (10 to 40C), Short-Form Detector
Functional (-15 to 45C)• Turn-On Verification• Survival Soaks
• Long-FormDetectorFunctional Test
Thermal VacuumTests
• Long-FormDetectorFunctionalTest
Pre-VibrationFunctional
BATC Acceptance
Review
• Verify MechanicalIntegrity Only
• Static Acceleration• Random Vibration• Sine Survey
FUV detectorPerformance tests
•Long-FormDetectorFunctional Test
• Bake-out• Cert at 40C
with TQCM
Vibration TestPreparation
• Linearity, QE,Flat Field• Background,stray light etc
• Final closeouts• Harness dress• Staking,torquing etc
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FUNCTIONAL TEST DESCRIPTION
• Short Functional System Test (no photons)– Power on, record currents
– Record housekeeping (temperatures, voltages, etc.)
– “+28 volt” margin test (±7 volt)
– Interface redundancy test
– TDC settings (walks, thresholds, stretches and shifts to nominal values)
– Acquire stims and analyze position and FWHM
– Verify counters
– Auxiliary power and door motor test
– HV operation (ramp HV to safe level)
– Power down
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FUNCTIONAL TEST DESCRIPTION
• Long Functional System Test (no photons)– Same as short functional system test with additions
– TDC command comprehensive test (all bits exercised)
• Long Functional System Test with Photons (in vacuum)– Same as above with additions
– Exercise door motor
– Exercise door actuator (limited life item, perform once during TV)
– HV to nominal operational voltage• Acquire background image
• Perform gain versus voltage characterization
• Brief flat field
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FUV SYSTEM ENVIRONMENTALQUALIFICATION OVERVIEW
• FUV detector environmental test requirements specified in the COSStatement of Requirements Document (COS-08-0003). Test plan outlinedin the Environmental Verification Plan (COS-UCB-007).
• Summary of Environmental Test Requirements:– EMI/EMC system compliance per MIL-STD-462 & MIL-STD-461C
– Vibration test compliance per GEVS-SE
– Magnetics test compliance per ST-ICD-02E
– Radiation: TID and SEE requirements per ST-ICD-02E• Parts procured and screened by GSFC
– Contamination/Cleanliness compliance per IN0090-111
– Thermal operational & survival limits per COS-08-0003
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FUV ENVIRONMENTAL TEST MATRIXPage 1 of 3
COS-UCB-007 APPENDIX A: Environmental Verification Matrix
QualificationRequirement Description
A T IAssembly Level Analysis/Test Description
Test FacilityDate
TestProcedure
Test Report # PFR #
SOR 5.1.2StructuralQualification
XDEB flight/DVAtest components
Sine-burst vibration test in 3 orthogonal axes at 1.25times the Limit Load, _9.7 g’s
AMES
SOR 5.1.3StructuralAcceptance
XDVA flightcomponent
Sine-burst vibration test in 3 orthogonal axes at the LimitLoad, _7.8 g’s
AMES
SOR 5.1.4Vibro-AcousticQualification
XDVA qualificationtest components
1 minute exposure in 3 orthogonal axes to the randomvibration environment stated in Table 5-1, COS-08-0003
AMES
SOR 5.1.5Vibro-AcousticAcceptance
XDEB /DVA flightcomponents
1 minute exposure in 3 orthogonal axes to the randomvibration test spectrum stated in Table 5-2, COS-08-0003
AMES
SOR 5.1.6 Stiffness XDEB /DVA flightcomponents
Sine survey tests demonstrating natural frequencygreater than the primary resonance stated in Table 5-3,COS-08-0003 (>75 Hz for DEB, > 125 Hz for DVA)
AMES
SOR 5.1.7 Shock - - - N/A No shock requirements N/A
SOR 5.1.8MechanicalFunction
X Door assembly
Identical FUSE door motor mechanism was life tested >3000 cycles (Report A00605), and won’t be repeated.Door function tested during assembly, & verified inThermal-Vac.
UCB
SOR 5.2.1AbsolutePressure
XDVA/DEB sub-assembly
Proper operation verified at atmospheric pressure and athigh vacuum.
UCB
SOR 5.2.2DifferentialPressure
XDEB sub-assembly
Components designed in accordance with conservativerule of thumb 1 in2 vents 1 ft3 volume.
UCB
SOR 5.3.1MagneticSusceptibility
XDVA sub-assembly
Shield design performance verified at static magnetic fieldof 2 Gauss and time varying component of +/- 1.8 Gauss
UCB4/99
COS-990426-JV COS-990426-JV N/A
SOR 5.3.2MagneticEmission
XDVA sub-assembly
Strongest magnetic field strength is < 0.25 Gauss at adistance of 3cm form the ion pump housing
UCB
SOR 5.4.1Total DoseEnvironment
X XDEB /DVA sub-assembly
Parts selected by GSFC/UCB to meet hardness > 10 krad GSFC
SOR 5.4.2SEEEnvironment
XDEB /DVA sub-assembly
Critical circuits have latch-up immunity to a LET of 37Digital devices selected with SEU immunity of at least 28
UCB/GSFC FMECA
SOR 5.5.1.1In-SpecTemperature
XDEB /DVA flightcomponents
Thermal-Vac: Short-form functional for 3 cycles between-10C and +45C. Long-form functional between +10C and+40C (@ 10 deg intervals).
UCB/SSL
SOR 5.5.1.2OperationalTemperature
XDEB /DVA flightcomponents
Thermal-Vac:Short-form functional for hot turn-on verification at +45CShort-form functional for cold turn-on verification at –20C
UCB/SSL
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FUV ENVIRONMENTAL TEST MATRIXPage 2 of 3
QualificationRequirement Description
A T IAssembly Level Analysis/Test Description
Test FacilityDate
TestProcedure
Test Report # PFR #
SOR 5.5.1.3 Survival Range XDEB /DVA flightcomponents
Thermal-Vac:Hot survival soak at +50CCold survival soak at –25C
UCB/SSL
SOR 5.5.1.4Non-TemperatureSensitive Items
XDEB/ DVAboard level
Non-vacuum thermal cycles UCB
SOR 5.5.1.5Thermal DesignRequirements
XDEB /DVAboard level
BASD Thermal Model BASD
SOR 5.5.2ThermalMonitoring andControl
X DEB /DVA flightcomponents
Heaters and thermisters controlled and monitored perSection 7.5, COS-UCB-001 (FUV Detector ICD)
UCB/SSL
SOR 5.5.3.1Voltage MarginTesting
XBoard or Sub-Assembly
+65C to –25C, Regulated Supply 1% Accuracy UCB
Ref. in UCB/EAG ElectronicsAssembly and
Test Flow Chart
SOR 5.5.3.2TemperatureTesting
XSub-Assembly,FUV Sub-System
Electronic Assembly: Non-Vacuum Thermal Soak at+80C max for 144 hrs, -25C min for 24 hrs.FUV Sub-System: Thermal-Vac testing (See VerificationMatrix for SOR 5.5.1.1,2,3)
UCB
Ref. in UCB/EAG ElectronicsAssembly and
Test Flow Chart
SOR 5.5.3.3Non-VacuumThermal Cycle
X Sub-Assembly6 to 12 cycles, 2C per minute, for 96 hrs. Soak for 2 hrsat each extreme (-20C to 65C).
UCB
Ref. in UCB/EAG ElectronicsAssembly and
Test Flow Chart
SOR 5.5.3.4Thermal-Vacuum Testing
XSub-Assembly,FUV Sub-System
Electronic Assembly: Thermal Vacuum Soak +65C maxfor 144 hrs, -25C min for 24 hrs.FUV Sub-System: See Verification Matrix for SOR5.5.1.1,2,3.
CASA
Ref. in UCB/EAG ElectronicsAssembly and
Test Flow Chart
SOR 6.1 Interface Voltage XDEB flightcomponents
Bench Tests UCB
SOR 6.2 In-Rush Current X DEB flightcomponents
Bench Tests UCB
SOR 6.3 Ground Location XFUV Sub-System Single-point ground per Section 7.3, COS-UCB-001 UCB
SOR 6.4Power SupplySpecifications
X XPower SupplyBoard Level
Tests performed at Battel Engineering, documentationsupplied with flight unit delivery to UCB
BattelEngineering
SOR 6.5.1CablingInterfaces
X XDEB /DVA flightcomponents
Connector pin-outs provided in Appendix C, COS-UCB-001. Safe-to-mate test prior to connection.
UCB
SOR 6.5.2 Grounding XDEB /DVAboard level
Grounding requirements per Section 7.3, COS-UCB-001 UCB
SOR6.5.3.1.1
ConductedEmissions X
FUV Sub-System
Narrowband conducted emissions tests on cabling from30Hz to 15kHz (CE01) and from 15kHz to 50MHz (CE03).Transient tests per CE07.
EMCEEngineering Mil-Std-462
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FUV ENVIRONMENTAL TEST MATRIXPage 3 of 3
Requirement Description Qualification Assembly Level Analysis/Test Description Test FacilityDate
TestProcedure
Test Report # PFR #
SOR6.5.3.1.2
RadiatedEmissions - - - Instrument N/A at FUV Detector System level (Waived) N/A N/A N/A N/A
SOR6.5.3.2.1
ConductedSusceptibility X
FUV Sub-System
CS01/CS02 tests at 1.5V peak-to-peak from 15Hz to50MHz
EMCEEngineering Mil-Std-462
SOR6.5.3.2.2
RadiatedSusceptibility
- - - N/A Waived N/A N/A N/A N/A
SOR 6.6CommunicationInterface X
FUV Sub-System
Hardware Interface Test using UCB DCE and BASDMEB simulators. Software Interface detailed in SoftwareVerification Plan.
BASD
SOR 7.4 Contamination X FUV Sub-System
Component level Bakeout. System certification at 40Cwith TQCM at –20C.
CASA
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FUV SYSTEM VIBRATION TESTING
• TEST OBJECTIVES– Demonstrate both the DVA & DEB are structurally sound such that their
functionality is not degraded after vibration, static load & acceleration testing• Functionality includes system electronic performance & mechanical performance
• TEST LEVEL DESCRIPTION– Vibration test levels taken from GEVS-SE
Item SOR Requirement Test Performed
DVA1 DVA2 DEB1 DEB2
StructuralQualification X X 9.7g
Sine Burst(15 Hz, 1 sec envelope, 5-
10 cycles at peak)
Vibro-AcousticQualification
X XSOR
Table 5-1Random Vibration
(1 min per axis)
StructuralAcceptance
X X X 7.8gSine Burst
(15 hz for 1 sec)
Vibro-AcousticAcceptance
X X XSOR
Table 5-2Random Vibration
(1 min per axis)
>125Hz for DVAStiffness X X X X
>75Hz for DEBSine Sweep
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
DETECTOR VIBRATION TEST PLAN
• Facilities– Test to be carried out at the NASA AMES test facility
• Plan/Status– First Subsystem vibration test to be to Qualification Levels (proto-flight)
– Delicate DVA interior hardware passed early Qualification Level vibration :• Brazed Body Assembly (BBA)
• Anode Cradle/Pogo/Bellows assembly
• Ion Repeller Grid
• Second Subsystem vibration to acceptance levels
• Test Configuration– Sine survey performed before and after each axis vibration
– Ion Pumps powered throughout testing via external HV supply
– Units attached to shake fixture at their flight structural I/F’s
– UCB and GSFC QA representative in attendance throughout
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
VIBRATION TEST PROCEDURE FLOW
• Detector System Long Functional Test performed at UCB prior to shake– Detector door operation verified in vacuum chamber
– Detector electronic performance verified
• Detector system (bagged, with N2) driven to NASA AMES on shippingplate
• DVA and DEB max dummies vibrated immediately prior to flight items
• Comparison Sine sweep before and after each shake axis
• Ion Pump current monitored throughout DVA shake (monitors DVApressure)
• Hardware visually inspected prior to and after each axis shake
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FUV DETECTOR EMI/EMC TESTING
• TEST OBJECTIVES– Demonstrate that the FUV system is compliant with selected conducted
emission & susceptibility tests defined per MIL-STD-461C and MIL-STD-462• Radiated emissions & susceptibility have been deemed not applicable at the FUV
Detector sub-system level by the HST project.
• TEST LEVELS DESCRIPTION– Conducted Emission test methods CE01, CE03 & CE07 on the 28V primary
power input line
– Conducted Susceptibility test methods CS01,CS02 & CS06 (modified) on the28V primary power line at a test voltage of 21V
• Voltages and currents measured as specified in the HST-COS FUV Detector EMCControl Plan & Performance Requirements Specification (UCB-COS-PLN-1137)
• Performance susceptibility assessed from STIM data (position and FWHM)
• Emissions assessed with HV applied to detector (at a safe level)
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
EMI/EMC Test Circuit & Test Levels
IN OUT
R
B
R
B
L1R1
L2
R2
R3
R4
R5
R6
R7
L3
C1 = 19000µFL2 = L3 = 1µHR1 = 330, 5WR2 = R5 = 24?R3 = R6 = 0.1?R4 = R7 = 0.3?
LISN for conducted emission testing
CE03 Narrowband Emissions
0
20
40
60
80
100
1.E+04 1.E+05 1.E+06 1.E+07 1.E+08
Frequency
CE 01 Narrowband Emissions
406080
100120140
1.00E+01 1.00E+02 1.00E+03 1.00E+04 1.00E+05
Frequency
dB
mic
ro a
mp
s
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
EMI/EMC TEST PLAN
• Facilities– Tests to be carried out at EMCE Engineering (Fremont, CA) who performed a
more extensive set of EMI/EMC tests on the FUSE detector system in 1996(FUSE test report available for inspection)
– LISN circuit provided by UCB
• Test Configuration– DVA and DEB with flight configured harnessing attached to the shipping plate
– Ion Pumps powered throughout testing via IPGSE to maintain DVA vacuum.Power may be removed for brief periods during conducted emissions testing asrequired.
– Detector HV applied only at “safe” turn-on level
– Data logged with FUV EGSE & Assembly Travelers
– UCB and GSFC QA representative in attendance throughout
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
EMI/EMC TEST PROCEDURE FLOW
• FUV “Short” Functional test performed at UCB prior to delivery to EMCE– Stim (X,Y) positions and FWHM
– Housekeeping T/M values logged
• Pre-EMI/EMC “Short” Functional test performed upon arrival at EMCE– Compare with UCB values
• CE-01, CE-03,CE-07 performed with detector at safe HV
• CS-01 and CS-02 performed with continuous collection of stim data
• Post EMI/EMC “Short” Functional test performed at UCB after completionof testing at EMCE
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FUV SYSTEM THERMAL VACUUMTESTING
• TEST OBJECTIVES– Demonstrate both the DVA & DEB can:
• Survive after soaks at hot and cold temperature extremes
• Perform nominally throughout thermal vacuum temperature cycling
• TEST LEVELS– Hot Survival = 50C, Cold Survival = -25C
– Hot Operate Limit = 45C, Cold Operate Limit = -20C
– Hot In-Spec Limit = 40C, Cold In-Spec Limit = 10C
– Will perform 1 hot & cold survival soak cycle followed by 5 thermal cyclesbetween 0C and 40C
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FUV Thermal Vacuum Test Configuration
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FLIGHT THERMAL LIMITS andPREDICTIONS
• Flight Temperature Limits per COS-UCB-001
• Below we give the BATC predictions for in-flight temperatures (°C) of thekey components of the FUV system:
Component With ACS Without ACSHot Op Cold Op Cold safe Cold Op Hot Op
DVA 26 25 13 27 32Charge Amps 28 26 9 27 34DVA I/F 21 20 2 20 29DEB TDC’s 28 23 -14 19 36DEB I/F 17 13 -14 10 26
ITEMSHOT
SURVIVALHOT
OPERATINGHOT
IN-SPECCOLD
IN-SPECCOLD
OPERATINGCOLD
SURVIVAL
DVA +50°C +40°C +40°C +10°C -20°C -25°C
DEB +60°C +50°C +40°C +10°C -20°C -25°C
All temperatures are as measured at the component thermal interfaces.
In-Spec Limits are the temperatures within which the detector subsystem will be verified to operate withinthe specifications defined by COS-08-0003 Statement of Requirements for the HST-COS FUV Detector.Operating Limits are temperatures within which the detector subsystem may be safely operated.Survival Limits are the temperatures beyond which detector components may be damaged.
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FUV THERMAL CYCLE PROFILECOS Detector T-V & Cleanliness Test Profile
-30
-20
-10
0
10
20
30
40
50
60
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FUV THERMAL VACUUM TEST PLAN
• Facilities– Tests to be carried out in the University of Colorado “Betty” T-V chamber at
CASA
– UCB to supply T-V mounting plate for the DEB and DVA
– UCB to provide all EGSE and external HV supply for ion pumps
– FUV system contains thermistors that monitor each electronics boardtemperature and several DVA temperatures, U of Co to provide extrathermistors for additional temperature monitoring
– UCB to provide a UV lamp (ex-FUSE flight stimulation lamp) that will bepowered in the T-V chamber to provide a UV photon stimulus to the detector
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FUV SYSTEM CLEANLINESSCERTIFICATION
• TEST OBJECTIVES
– Ensure that the FUV systems (DEB + DVA) meets the cleanliness andoutgassing requirements of the COS Contamination Control Plan (IN0090-111)
• TEST LEVELS– Particulates
• Meet level 150A (mil Std 1246) - interior surfaces
• Meet level 400A (mil Std 1246) - exterior surfaces
– Molecular• Outgassing rate < 4.3 x 10-13 g/cm3 (TQCM at -20C, hardware at 40C)
• Actual measured frequency change of TQCM expected from system in the certification set-upoutlined in memo COS-000503-MAG
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
CLEANLINESS CERTIFICATION PLAN
• TEST FACILITIES
– Certification to be carried out inside the U of Co “Betty” T-V chamber
– Faraday Labs TQCM mounted on chamber plate, held at -20C
• TEST PLAN (Outgassing)– FUV system (power off) heated to 50C and baked out for 72 hours (temperature
limit defined by detector door paraffin actuator)
– Temperature lowered to 40C and TQCM certification performed
• TEST PLAN (Particulates)– Prior to insertion into T-V chamber, FUV system inspected for particulates
using UV black lamp and tape lifts
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
FUV Detector Shipping Plan
• All shipment activities governed by :
– Handling Procedures (ESD etc)
– Contamination Control
– Detector Safety (constant power to ion pumps to maintain vacuum)
• Transportation Configuration– DEB and DVA (double bagged)) mounted at their flight interfaces to a shipping
plate (same as the T-V mounting plate)
– Shipping plate mounts on vibration damper supports within a shipping container
– Require accelerometers to be mounted to frame
– Container placed on wooden blocks and strapped to the shipping truck floor
– EGSE and IPGSE racks padded and strapped to wall of truck
– Other GSE shipped in crates
– No special environmental requirements (humidity, temperature etc)
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Space Telescope ProgramsHubble Observatory
HST-COS FUVPER 11/8/00
Detector Shipping Plan (cont)
• Power to detector ion pumps– UPS Battery supplies AC voltage to Ion Pump GSE Controllers which in turn
power the detector ion pumps to maintain vacuum within the DVA
– UPS lifetime ~ 48 hours (also powered during overnight stay)
• Truck– Rental truck (2 drivers)
– Supported by car (2 drivers) in cell phone communication with truck